DESIGN DIVISION

ES,MUMBAI
ISO-9001:2000

FUNCTIONAL
SPECIFICATION FOR
CHAIN PULLEY BLOCK
(For Onshore Projects)
DE-BOTTLENECKING OF
ETP AT CPF,GANDHAR

Spec. No.
REV. NO.
Discipline:
MECHANIICAL
SHEET 1

FUNCTIONAL SPECIFICATION
FOR
CHAIN PULLEY BLOCK

OF 9

DESIGN DIVISION
ES,MUMBAI
ISO-9001:2000

FUNCTIONAL
SPECIFICATION FOR
CHAIN PULLEY BLOCK
(For Onshore Projects)
DE-BOTTLENECKING OF
ETP AT CPF,GANDHAR

Spec. No.
REV. NO.
Discipline:
MECHANIICAL
SHEET 2

OF 9

FUNCTIONAL SPECIFICATION FOR CHAIN PULLEY BLOCK

1.0

GENERAL

1.1

This specification along with data sheets, other specifications & attachments to inquiry
/ order describes and constitutes the minimum requirement for Chain Pulley block with
or without trolley for Hazardous area application.
The intent of these requirements is to supplement the requirements as given in data
sheets, other specifications and other applicable standards / codes referred to in data
sheets / specifications.

1.2

Contractor and vendor shall make all possible efforts to comply strictly with
the requirements of this specification and other aforesaid specifications / attachments
to inquiry / order and no deviation and exception from this specification shall be
permitted without written approval of Company.
In case any deviations are considered essential by vendor, these shall be separately
listed in vendors offer titled as List of deviations / exceptions to the inquiry
document , supported with proper reasons for the deviation for Companys
considerations. Any deviation indicated elsewhere, but not listed in the deviation list
shall not be considered applicable.

1.3

Except as specified herein, the chain pulley block shall be designed, manufactured,
tested and supplied in accordance with data sheets / specifications / applicable
standards / codes ( latest edition ). In the event of any contradiction, the following order
of precedence shall govern: o

Equipment data sheet

DESIGN DIVISION
ES,MUMBAI
ISO-9001:2000

FUNCTIONAL
SPECIFICATION FOR
CHAIN PULLEY BLOCK
(For Onshore Projects)
DE-BOTTLENECKING OF
ETP AT CPF,GANDHAR

Job specification / This specification

Other reference specifications / attachments.

International standards / codes as applicable.

Spec. No.
REV. NO.
Discipline:
MECHANIICAL
SHEET 3

OF 9

As a general rule, the most stringent requirement shall apply.

1.4

Contractor / vendor shall seek Company's approval regarding such features which are
not specified by Company but job requirements call for purchaser decision on these
matters.

1.5

Compliance with this specification shall not relieve Contractor / vendor of the
responsibilities of furnishing equipment and accessories / auxiliaries of proper design,
materials and workmanship to meet the specified start up and operating conditions.
In case Contractor / vendor considers requirement of additional instrumentation,
controls, safety devices and any other accessories / auxiliaries essential for safe and
satisfactory operation of the equipment, he shall recommend the same along with
reasons in a separate section along with his offer and include the same in his scope of
supply.

1.7

1.8
1.9

1.10
1.11
1.12
1.13

Chain pulley block vendor / manufacturer shall have adequate engineering,

manufacturing and testing facilities conforming to national / international standards /
codes.
The chain pulley block offered shall be from a regular and established manufacturer of
chain pulley blocks.
The chain pulley block offered shall be from the existing regular manufacturing range
of chain pulley block vendor / manufacturer and already type tested at either
manufacturers works or outside. Vendor's / manufacturers catalogue and general
reference list shall be furnished along with the offer.
Chain pulley block vendor / manufacturer shall assume responsibility for satisfactory
performance of the equipment for the specified service.
Chain pulley block and all auxiliaries shall be suitable for the specified area
classification.
Chain pulley block vendor / manufacturer shall not offer any alternative designs.
Special tools and tackles required either for installation / erection or operation and
maintenance of the chain pulley block shall be included in vendors scope of supply.

2.0

CODES AND STANDARDS

2.1

The following latest edition codes, standards and recommended practices shall govern:
IS:3832

Specification for Hand operated Chain Pulley Blocks.

IS:2429

Specification for Round steel short link chain.

IS:6216

Specification for Short link chain, grade T ( 8 ) calibrated.

DESIGN DIVISION
ES,MUMBAI
ISO-9001:2000

FUNCTIONAL
SPECIFICATION FOR
CHAIN PULLEY BLOCK
(For Onshore Projects)
DE-BOTTLENECKING OF
ETP AT CPF,GANDHAR

Spec. No.
REV. NO.
Discipline:
MECHANIICAL
SHEET 4

OF 9

IS:8610 Specification for Point hook with shank up to 25 Tons trapezoidal section.
Other international standards may also be acceptable subject to their being equivalent
or superior with prior approval of Company.
2.2

For provisions not covered by the above codes & standards, applicable engineering
practices & norms shall govern.

3.0

TECHNICAL REQUIREMENTS

3.1.1 Design and manufacture of chain pulley block with or without trolley shall be
consistent with capacity, lift, headroom and other parameters as specified in the data
sheets.
3.1.2 In design of chain pulley blocks, care shall be taken for following features.
-

Minimum effort to lift a specified load.

Self-braking system for holding the load in any position.

Even loading of bearings.

Ease of installation and maintenance.

Compact design.

For chain pulley blocks operating in hazardous area, the materials for non-lubricated
rubbing parts shall be of non-sparking type ( non-ferrous ).
The suggested materials for such components are as follows:

Ratchet wheel, load chain wheel, hand : Solid construction in Phosphor

chain wheel, chain guides for lifting
bronze or Gun metal or brass.
mechanism.
Rims of un-geared runners, geared : Phosphor bronze or Gun metal
runners, hand chain wheel and hand
or brass.
chain wheel guides for trolley
mechanism.
:
Load hook

Forged brass /
bronze

Aluminium

All materials used in construction of different components shall individually conform

to IS: 3832.

DESIGN DIVISION
ES,MUMBAI
ISO-9001:2000

3.2

FUNCTIONAL
SPECIFICATION FOR
CHAIN PULLEY BLOCK
(For Onshore Projects)
DE-BOTTLENECKING OF
ETP AT CPF,GANDHAR

Spec. No.
REV. NO.
Discipline:
MECHANIICAL
SHEET 5

OF 9

Frame
The frame shall be designed for proper strength built from steel plates with bolted /
welded construction.

3.3

Gear
Chain pulley blocks shall be supplied with helical or worm gear. The gear shall be
designed for surface durability. All gears shall be machine cut from alloy steel and case
hardened. In case of enclosed gearing, means shall be provided for ample lubrication.

3.4

Load Brakes
Chain pulley block shall be provided with an automatic mechanical Ratchet and Pawl
type load brake which will prevent self lowering of the load and sustain and hold the
load in all working positions. The load brake shall allow smooth lowering of the load
without serious overheating which may impair efficient working of the block. The Pawl
& Ratchet shall be made of steel hardened and tempered to provide satisfactory degree
of wear resistance. The hardness of Pawl tip and Ratchet shall not be less than 40 and
30 HRC respectively.

3.5

Bearing
Only antifriction bearing shall be used. All the bearing shall be adequately lubricated
type and arrangement of lubrication shall be clearly indicated on the cross section
drawings.

3.6

Hooks

3.6.1 The hooks ( top and bottom ) shall conform to IS: 8610. The bottom hook block shall
be provided with thrust bearing to enable it to free swivel in the loaded condition
without twisting the load chain. The top hook if required to swivel shall also be
provided with thrust bearing. Hooks shall be provided with safety latches to prevent
accidental unhooking.
3.6.2 Suspension fitting other than hook shall be of sufficient strength to afford a static factor
of safety of not less than 4.
3.7

Load Chain
The load ( link ) chain shall be conforming to minimum Grade 80 of
The chain shall be pitched and polished.

3.7.1. Hand Chain

IS: 6216.

DESIGN DIVISION
ES,MUMBAI
ISO-9001:2000

FUNCTIONAL
SPECIFICATION FOR
CHAIN PULLEY BLOCK
(For Onshore Projects)
DE-BOTTLENECKING OF
ETP AT CPF,GANDHAR

Spec. No.
REV. NO.
Discipline:
MECHANIICAL
SHEET 6

OF 9

The hand chain shall be conforming to grade 30 of IS: 2429 ( Part-II ). The chains shall
be pitched & polished. The chain link dimension shall be conforming to 6.3 mm
nominal diameter chain of IS:2429 ( Part-I ). The length of chain shall be such that the
lowest point of loop shall be 0.4 meter above the operating level.
3.8

Chain Wheel

3.8.1 Wheel for load chain shall be made of material suitable for use with load chain
employed and be of adequate strength and shall be designed to ensure effective
operation.
3.8.2 Wheel for hand chain shall be provided with flange.
3.8.3 Wheels shall be provided with guides to prevent sagging of chain.
3.9

Idler Wheel
The chain pulley blocks shall be provided with idler wheels so shaped as to avoid
twisting of the chain when passing round. The pitch diameter of the idler wheels shall
not be less than 16 times of size of the chain.

3.10

Trolley

3.10.1 The trolley for the chain pulley block shall be geared type, fabricated construction, 4
wheeled, driven by hand chain and shall have provision for mounting the chain pulley
block.
3.10.2 Trolley shall be designed to suit the suitable joist size and the hoisting capacity.
4.0

INSPECTION AND TESTING

4.1

Unless otherwise specified all the chain pulley blocks shall be stagewise inspected and
witness tested by third party inspection agency ( at Contractors cost ). However,
Company reserves the right to depute its authorized representative in addition to third
party inspection agency.

4.2

As a minimum, tests shall be carried out as specified in the data sheets and elsewhere (
if any ). However, Company reserves the right to witness all mechanical and
performance tests.

4.3

Contractor / vendor shall give at least 15 days notice prior to commencement of testing.

4.4

Vendor shall notify his sub-vendor of Company's inspection and testing requirements.

4.5

All inspections shall be regarded as check-up only. However acceptance of shop test
shall not absolve / relieve Contractor and vendor from any of their responsibilities in
any way, whatsoever.

4.6

All controls and safety devices shall be tested for satisfactory operation and
settings.

DESIGN DIVISION
ES,MUMBAI
ISO-9001:2000

FUNCTIONAL
SPECIFICATION FOR
CHAIN PULLEY BLOCK
(For Onshore Projects)
DE-BOTTLENECKING OF
ETP AT CPF,GANDHAR

Spec. No.
REV. NO.
Discipline:
MECHANIICAL
SHEET 7

OF 9

4.7

Companys representative shall have access to vendors / manufacturers shop as well

as to sub-vendors shop at all times during manufacturing of the equipments and
vendor / manufacturer shall provide all requisite facilities including necessary
monitoring and measuring devices to Companys representative for carrying out
satisfactory inspection and witnessing the tests.

4.8

Equipment shall be subjected to stagewise inspection and testing at vendors / subvendors works by third party inspection agency and / or by Companys authorized
representative. Vendor shall furnish schedules for all inspections and tests to be
conducted on all the equipment and auxiliaries in his scope of supply in a single
document titled Inspection & Test Plan within four weeks of placement of purchase
order / letter of intent for Company's review and approval. The extent of Company's
participation and schedule of submission of inspection and test procedures as specified
in inquiry / order shall also be reflected in 'Inspection and Test Plan'.

4.9

Each chain pulley block shall be subjected to one and a half times the safe working
load through a length of lift which will ensure that every part of the block mechanism
and each tooth of gears come under load. The trolley shall be tested for smooth
operation when loaded.

4.10

Certificate of test and examination shall be issued with all the chain pulley giving the
following informations.
i)

Safe working load.

ii)

Range of lift.

iii)

Load chain size and grade.

iv)

Proof load applied.

5.0

GUARANTEE / WARRANTY

5.1

Contractor and equipment vendor shall guarantee all equipments and components (
including all auxiliaries ) supplied in respect of design, materials and fabrication and /
or workmanship for 24 months from the date of supply or 12 months from the date of
successful commissioning, whichever is later.

5.2

If any defect or mal-performance occurs during the guarantee period, Contractor and
equipment vendor shall make all necessary alteration, repairs, and replacements free of
charge.

5.3

Companys approval of the equipment design shall not relieve Contractor and
equipment vendor of their responsibilities to ensure satisfactory performance of the
items supplied.
Contactor and equipment vendor shall guarantee that all materials used are new,
satisfactorily passed through acceptance procedure and is acceptable in quality, form
and appearance.

5.4

FUNCTIONAL
SPECIFICATION FOR
CHAIN PULLEY BLOCK
(For Onshore Projects)

DESIGN DIVISION
ES,MUMBAI
ISO-9001:2000

5.5

DE-BOTTLENECKING OF
ETP AT CPF,GANDHAR

Spec. No.
REV. NO.
Discipline:
MECHANIICAL
SHEET 8

OF 9

Equipment vendor shall be responsible for overall performance of the equipment

6.0

PROTECTION AND PAINTING

6.1

All exposed carbon steel parts to be painted shall be thoroughly cleaned from inside
and outside to remove scale, rust, dirt and other foreign materials by wire brushing and
sand blasting, as applicable. Minimum acceptable standard in case of power tool
cleaning shall be St. 3 and in case of blast cleaning shall be Sa 2 1/2 as per Swedish
Standard SIS: 055900 ( latest edition ).

6.2

Non-ferrous materials, austenitic stainless steels, plastic or plastic coated materials and
insulated surfaces of equipment not be painted.

6.3

Stainless steel surfaces both inside and outside shall be pickled and passivated.

6.4

Machined and bearing surface shall be protected with varnish or thick coat of grease.

6.5

Depending on the environment, following primer and finish coats shall be applied.
Environment
1.

2.

3.

Normal

Description

Industrial

Corrosion Industrial

Coastal
Marine

and

Primer

2 coats of Red oxide zinc chromate,

each 25 microns (min.) thick.

Finish

2 coats of Synthetic enamel, each

25 microns ( min. ) thick.

Primer

2 coats of Epoxy zinc chromate

each 35 microns ( min. ) thick.

Finish

2 coats of Epoxy high build paint,

each 100 microns ( min.) thick.

Primer

2 coats of High build chlorinated

rubber zinc phosphate each 50
microns ( min. ) thick.

Finish

2 coats of Chlorinated rubber paint

each 35 microns ( min. ) thick.

4.

All environments
(Temp. 80-250C)

Finish

2 coats of Heat resistant

Aluminium paint suitable for 250C
each of thickness 20 microns.

5.

All environment
(Temp. 250-400C)

Finish

2 coats of Heat resistant

Aluminium paint suitable for 400C
each of thickness 20 microns.

DESIGN DIVISION
ES,MUMBAI
ISO-9001:2000

FUNCTIONAL
SPECIFICATION FOR
CHAIN PULLEY BLOCK
(For Onshore Projects)
DE-BOTTLENECKING OF
ETP AT CPF,GANDHAR

Spec. No.
REV. NO.
Discipline:
MECHANIICAL
SHEET 9

OF 9

( All values refer to dry film thickness )

6.6

The colour of finish coat shall be intimated to vendor after placement of order.

7.0

PACKAGING AND IDENTIFICATION

7.1

All packaging shall be done in such manner as to reduce the volume. The equipment
shall be dismantled into major components suitable for shipment and shall be properly
packed to provide adequate protection during shipment. All assemblies shall be
properly match marked for site erection.

7.2

Attachments, spare parts of the equipment and small items shall be packed separately in
wooden-cases. Each item shall be appropriately tagged with identification of main
equipment, item denomination and reference number of the respective assembly
drawings.

7.3

Detailed packing list in water-proof envelope shall be inserted in the package together
with equipment.

7.4

Each equipment shall have an identification plate giving salient equipment detail / data,
name of manufacturer, make / model, equipment number, year of manufacture etc.

8.0

SPARE PARTS

8.1

Contractor / vendor shall submit recommended list of spare parts with recommended
quantities for one year as well as first two years of operation of the equipment
alongwith the itemized price list for all parts. Proper coding and referencing of spare
parts shall be done so that later identification with appropriate equipment will be
facilitated.

8.2

Recommended spares and their quantities should take into account related factors of
safety, equipment reliability, effect of equipment downtime upon production, cost of
parts and availability of vendors service facilities around proposed location of
equipment.

8.3

Vendor shall also submit a list of recommended commissioning spares with quantities
and the itemized prices. However supply of commissioning spares shall be in
Contractors / vendors scope of supply without any extra cost to Company.